Yanmar 6AYM-GTE, 6AYM-ETE & 6AYM-STE Marine Propulsion Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 6AYM-GTE, 6AYM-ETE & 6AYM-STE Yanmar Marine Propulsion Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

This service manual describes the construction and functions of the major parts of the 6A YMGTE, 6A YM-ETE, 6A YM-STE engine and illustrates the disassembly and assembly procedures (standard servicing procedures) necessary for maintaining and servicing the engine.


APPLICABLE MODELS :

Yanmar 6AYM-GTE
Yanmar 6AYM-ETE
Yanmar 6AYM-STE


TABLE OF CONTENTS :

1. General
2. Disassembly and reassembly
3. Preparation Before Checking and Servicing
4. Test running
5. Long storage
6. Troubleshooting
7. Service standards
8. Maintenance Checking
9. Service Standard
10. Tightening Torque for Major Bolts and Nuts


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Code No. : OB6AY-G00201
Total Pages : 301


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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COVER
FOREWORD
CONTENTS
FOR SAFETY
1. SAFETY LABELS
2. Safety Precautions
3. Warning labels
1. General
1.1 Exterior views
1.2 Cross Sectional View
1.3 Engine specifications
1.4 Drawings of Engine Outline
6AYM-GTE ,6AYM-ETE
6AYM-STE
1.5 Piping Diagram
1.6 Fuel oil, lubricating oil and cooling water
1.6.1 Fuel oil
1.6.2 Lubricating oil
1.6.3 Cooling Water (Engine Jacket Water)
2. Disassembly and reassembly
2.1 Disassembly and reassembly precautions
2.2 Disassembly and reassembly tools
2.2.1 General hand tools
2.2.2 Special hand tools
2.2.3 Measuring instruments
2.2.4 Other material
2.3 Disassembly procedures
2.4 Reassembly
2.5 Wire harness
3. Preparation Before Checking and Servicing
3.1 Cylinder Head
3.1.1 Inspecting the cylinder head
3.1.2 Valve seat correction procedure
3.1.3 Intake/exhaust valves, valve guides
3.1.5 Valve rotator
3.1.4 Valve springs
3.1.6 Nozzle sleeve
3.1.7 Assembling the cylinder head
3.1.8 Measuring top clearance
3.1.9 Intake and exhaust rocker arms
3.1.10 Push rod
3.1.11 Adjustment of valve clearance
3.2 Cylinder block
3.2.1 Cylinder block
3.2.2 Checking the parts
3.3 Cylinder liner
3.3.1 Measurement of liner
3.3.2 Insertion of liner
3.3.3 Measurement of projection
3.4 Piston and piston pins
3.4.1 Piston
3.4.2 Piston pin
3.4.3 Piston rings
3.5 Connecting rod
3.5.1 Inspecting the connection rod
3.5.2 Crank pin metal
3.5.3 Piston pin bearing
3.5.4 Assembling piston and connecting rod
3.6 Crankshaft and main bearing
3.6.1 Crankshaft
3.6.2 Main bearing
3.7 Camshaft and Tappets
3.7.1 Camshaft
3.7.2 Tappets
3.8 Timing gear
3.8.1 Inspecting the gears
3.8.2 Gear timing marks
3.8.3 Fresh water pump & Alternator driving gear (OFW)
3.9 Flywheel and housing
3.9.1 Specifications of flywheel
3.9.2 Ring gear
3.9.3 Position of top dead center
3.9.4 Dimensions of flywheel
3.9.5 Dimensions of front P.T.O and mounting flange
3.10 Fuel injection equipment
3.10.1 Fuel Oil System
3.10.2 Fuel injection pump/governor
3.11 Governor
3.11.1 Description
3.11.2 Disassembly of Governor
3.11.3 Inspection
3.11.4 Assembly
3.11.5 Adjustment
3.12 Disassembly, Reassembly and Inspection of Fuel injection pump
3.12.1 Disassembly of fuel injection pump
3.12.2 Inspection of fuel injection pump
3.12.3 Reassembly of fuel injection pump
3.12.4 Adjustment of fuel injection pump
3.13 Fuel feed pump
3.14 Adjusting the injection timing
3.15 Fuel injection Nozzle
3.15.1 Functioning of fuel injectionnozzle
3.15.2 Fuel injection nozzle disassembly
3.16 Boost Compensator
3.16.1 Performance
3.16.2 Equipment
3.17 Troubleshooting of fuel oil system
3.18 Fuel Filter
3.18.1 Fuel filter specifications
3.18.2 Fuel Filter inspection
3.18.3 Water separator
3.19 Lubrication system
3.19.1 Lubrication system
3.19.2 Lube oil pump
3.19.3 Oil pressure control valve construction
3.19.4 Lube oil filter
3.19.5 Lube oil cooler
3.19.6 Piston Cooling Nozzle
3.19.7 Gear waste oil pump (Optional)
3.20 Cooling water system
3.20.1 Cooling water system
3.20.2 Seawater pump
3.20.3 Checking and Replacement of Anticorrosive Zincs
3.20.4 Fresh water pump
3.20.5 Fresh Water Line
3.20.6 Fresh Water Cooler
3.20.7 Pressure cap and Coolant recovery tank
3.20.8 Thermostat
3.20.9 Seawater System Cleaning
3.20.10 Fresh Water System Cleaning
3.21 Turbocharger
3.21.1 Specification
3.21.2 Construction and function of turbocharger
3.21.3 Standards for maintenance and check
3.21.4 Periodical checking procedure
3.21.4.1 Periodical checking interval
3.21.4.2 Checking procedure
3.21.5 Disassembly procedure
3.21.5.1 Preparations for disassembly
3.21.5.2 Check before disassembly
3.21.6 Disassembly
3.21.7 Cleaning and checking procedure
3.21.7.1 Cleaning
3.21.7.2 Checking procedure
3.21.8 Reassembling procedure
3.21.8.1 Preparations for reassembly
3.21.8.2 Reassembling procedure
3.21.9 Handling after reassembly
3.21.9.1 Precautions for mounting the turbocharger to the engine
3.21.10 Troubleshooting
3.21.10.1 Exhaust gas is dense
3.21.10.2 Whitish exhaust gas
3.21.10.3 Too early oil shortage
3.21.10.4 Output drop
3.21.10.5 Poor follow-up of supercharger
3.21.10.6 Unusual sound or vibration
3.22 Electrical System
3.22.1 starting motor
3.22.2 Alternator
3.22.3 Wiring Diagram (1 pole type)
3.22.4 Wiring Diagram (1 pole type with Air Heater)
3.22.5 Wiring Diagram (2 pole type) (Option)
3.22.6 Wiring Diagram (2 pole type with Air Heater)
3.22.7 Instrument Panel
3.23 Starting Air Motor (Special order)
3.23.1 Specifications
3.23.2 Piping Layout
3.23.3 Sectional View
3.23.4 Outline of Consutruction and Its Function
3.23.5 Inspection, Maintenance and Adjustment
3.23.6 Overhaul
4. Test running
4.1 Preliminary precautions
4.2 Test running procedure
4.2.1 Check points and precautions during running
5. Long storage
6. Troubleshooting
6.1 Preparation before troubleshooting
6.2 Fault-finding chart
7. Service standards
7.1 Engine tuning
7.2 Engine body
7.2.1 Cylinder head
7.2.2 Camshaft and gear train
7.2.3 Cylinder block
8. Maintenance Checking
8.1 Precautions in Maintenance Checking
8.2 Table of Periodical Checking
9. Service Standard
10. Tightening Torque for Major Bolts and Nuts
10.1 Tightening Torque for Major Bolts and Nuts
10.2 Method of Tightening Connecting Rod Nuts
10.3 Method of clamping cylinder head bolts
Service Network
COLOPHON
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